MAZDA 626 1987 Workshop Manual

DISASSEMBLY (INJECTION PUMP) 1 C
INJECTION PUMP
76G01C-082
1. No.3 engine mount and idler
2. Injection pipe
3. Injection pump
4. Oil level gauge and stay
5. Oil pipe
6. Fuel feed pipe
7. Oil pressure switch
8. Water pipe
9. Water pump
Disassembly Note
Injection pump
Remove the injection pump with its brackets.
If separate them, adjust the injection timing after in-
stalling the timing belt referring to Section 4D.
76G01C-083
1C-39

1 C DISASSEMBLY (CYLINDER HEAD)
CYLINDER HEAD
76G01C-079
1. Thermostat cover
2. Thermostat
3. Thermostat case
4. Front and rear engine
hanger
5. Fuel leak pipe
6. Injection nozzle
7. Glow cord
8. Glow plug
9. Camshaft cap
10. Oil seal
11. Camshaft
12. Cylinder head bolt
13. Cylinder head and gasket
14. Tappet and adjusting disc
15. Valve keepers
16. Upper spring seat
17. Valve spring
18. Valve
19. Lower spring seat
20. Valve seal
21. Valve guide and clip
1C-40

DISASSEMBLY (CYLINDER HEAD) 1 C
76G01C-085
76G01C-086
76G01C-087
A.
Disassembly Note
Camshaft
During disassembly, clean the bearings and journals,
and measure the following:
1. Camshaft end play. (Refer to page 1C—55)
2. Camshaft journal oil clearance . (Refer to page
1C—54)
Camshaft cap
Loosen the camshaft cap nuts in two or three steps
in the order shown in the figure.
Cylinder head bolt
1. Loosen the cylinder head bolts in two or three steps
in the order shown in the figure.
2. Remove the cylinder head by tapping the cylinder
head with a plastic hammer.
Adjusting disc and tappet
Remove the adjusting discs and tappets as a set.
Caution
All adjusting discs and tappets should be dis-
assembled in a way so that correct reassem-
bly can be performed.
4BG01B-094
1C—41

1 C DISASSEMBLY (CYLINDER HEAD)
Valve spring
Remove the valve, spring seats and valve keepers
from the cylinder head with the SST.
76G01C-088
Valve seal
After removing the lower spring seats, remove the
valve seals with the SST.
76G01C-089
Ball
_ Combustion
"X^ chamber
Glow plug hole
Combustion chamber insert
Caution
Do not remove the combustion chamber in-
sert as the cylinder head and the combustion
chamber insert are machined together, re-
place the combustion chamber insert and cyl-
inder head as an assembly.
76G01C-090
1C-42

DISASSEMBLY (CYLINDER BLOCK) 1 C
CYLINDER BLOCK—I
76G01C-091
1. Clutch cover
2. Clutch disc
3. Flywheel
4. End plate
5. Oil pan
6. Oil strainer
7. Stiffener (RF-CX)
8. Rear cover
9. Timing belt pulley
10. Oil pump assembly
Flywheel
1. Install the SST to the flywheel.
2. Remove the clutch cover, clutch disc and flywheel.
Timing belt pulley
1. Reverse the direction of the SST.
2. Remove the timing belt pulley.
76G01C-092
1C—43

1 C DISASSEMBLY (CYLINDER BLOCK)
Oil pan
1. Remove the oil pan mounting bolts.
2. Insert a scraper or a suitable tool between the oil
pan and the stiffener to separate them.
Caution
Do not bend the oil pan when prying loose.
3. Remove the oil pan.
86U01X-072
1C—44

DISASSEMBLY (CYLINDER BLOCK) 1 C
CYLINDER BLOCK—II
76G01C-093
1. Connecting rod cap
2. Connecting rod bearing
3. Connecting rod and piston
4. Piston ring
5. Snap ring
6. Piston pin
7. Main bearing cap
8. Crankshaft
9. Main bearing
10. Pilot bearing
11. Oil jet
12. Cylinder block
Disassembly Note
Connecting rod and cap
During disassembly, clean the bearing, connecting
rod, and crankpin, and measure the following:
1. Connecting rod side clearance. (Refer to page
1C-67.)
2. Crankpin oil clearance.(Refer to page 1C—66.)
76G01C-094
1C-45

1 C DISASSEMBLY (CYLINDER BLOCK)
Piston and connecting rod
1. Before disassembling the piston and connecting
rod, check the oscillation torque as shown in the
figure. If the large end does not drop by its own
weight, replace the piston or the piston pin.
76G01C-095
2. Remove the snap rings from the piston.
3. Remove the piston pin with the SST.
76G01C-249
76G01C-096
Main bearing cap
During disassembly, clean the bearings, main jour-
nals, and caps, and measure the following:
1. Crankshaft end play. (Refer to page 1C—65.)
2. Main journal oil clearance. (Refer to page 1C—64.)
Pilot bearing
Remove the pilot bearing from the crankshaft with the
SST.
76G01C-097
1C—46

INSPECTION AND REPAIR 1C
INSPECTION AND REPAIR
1. Clean all parts, taking care to remove any gasket fragments, dirt, oil or grease, carbon, moisture
residue, or other foreign materials.
2. Inspect and repair must be performed in the order specified.
Caution
Be careful not to damage the joints or friction surfaces of aluminum alloy components (such
as the cylinder head or pistons).
86U01X-077
Cylinder Head
1. Inspect the cylinder head for damage, cracks, and
leakage of water or oil. Replace if necessary.
2. Measure the cylinder head distortion in the seven
directions shown in the figure.
Distortion: 0.10 mm (0.004 in) max.
76G01C-098
3. If the cylinder head distortion exceeds specificati-
on replace the cylinder head.
Height:
133.9—134.1 mm (5.272—5.280 in)
Caution
Do not attempt to repair a cylinder head by
milling or grinding.
76G01C-099
4. Measure the manifold contact surface distortion in
the three directions shown in the figure.
Distortion: 0.20 mm (0.008 in) max.
5. If distortion exceeds specification replace the cyl-
inder head.
76G01C-100
1C—47

1C INSPECTION AND REPAIR
Stem tip
Margin i
thickness
T
Valve face
angle
^45°
76G01C-101
76G01C-102
" & ©
JMFc
•^Caliper gauge
^V^r "M
m
Valve and Valve Guide
1. Inspect each valve for the following. Replace or
resurface if necessary.
(1) Damaged or bent stem
(2) Roughness or damage to face
(3) Damage or uneven wear of stem tip
2. Check the valve head margin thickness. Replace
if necessary.
Margin thickness mm (in)
RF-CX IN 1.80 (0.071) RF-CX EX 1.65 (0.065)
RF-N IN 0.80 (0.031) RF-N EX 0.80 (0.031)
3. Measure the valve length.
Length
IN : 106.9 mm (4.209 in)
EX: 106.8 mm (4.205 in)
4. Measure the valve stem diameter.
Diameter
IN : 7.970—7.985 mm (0.3138—0.3144 in)
EX: 7.965—7.980 mm (0.3136—0.3142 in)
5. Measure the valve guide inner diameter.
Inner diameter
IN : 8.025—8.045 mm (0.3159—0.3167 in)
EX: 8.025—8.045 mm (0.3159—0.3167 in)
76G01C-103
-Valve stem
Valve guide

Clearance
V
6. Measure the valve stem to guide clearance.
(1) Method No. 1
Subtract the outer diameter of the valve stem
from the inner diameter of the corresponding
valve guide.
Clearance
IN : 0.040—0.075 mm (0.0016—0.0030 in)
EX: 0.045—0.080 mm (0.0018—0.0031 in)
Maximum: 0.10 mm (0.004 in)
7.
If
the clearance exceeds the maximum, replace the
valve and/or valve guide.

76G01C-111

1C-48